KR20110001715A - High strength polypropylene staple fibers by high drawing and methods of the same, nonwoven made of them - Google Patents

Abstract

PURPOSE: High strength polypropylene staple fibers by high drawing and a method of the same, an a nonwoven material made of the fibers are provided to increase stretching degree through the addition of methyl acrylate. CONSTITUTION: Homopolyproplyene 90-99 weight% and carrier resin 1-10 weight% are mixed with each other. The carrier resin is formed by a copolymer of ethylene and methyl acrylate. Melt spinning is performed on the mixture and spun undrawn yarn is drawn at a drawing ratio of 3.0-5.0. The drawn yarn is crimped, and resin liquid including emulsion is attached on the surface of the drawn yarn. After thermal fixing of the drawn yarn, the drawn yarn is cut as staple fiber.

Description

High strength polypropylene staple fibers by high elongation and method for manufacturing the same, nonwoven fabrics thereof {High strength polypropylene staple fibers by high drawing and methods of the same, nonwoven made of them}

TECHNICAL FIELD The present invention relates to short polypropylene fibers, and more particularly, to high-strength polypropylene short fibers and a method for manufacturing the same, and a nonwoven fabric made therefrom by high stretchability.

Polypropylene fibers are generally hydrophobic and have a low melting point. However, polypropylene fibers have been used for light sportswear, etc., by using wicking properties, which are advantageous for moisture transfer.

In general, in the production of short fibers from polypropylene polymer, a polymer is mixed with a predetermined amount of additives and melt-extruded by a conventional commercial process to produce fibers, and then a crimped and cut to a predetermined length is applied to the melt-extruded fibers. It goes through the process of.

Non-woven fabrics are fabrics made by bonding or tangling textile aggregates by mechanical or chemical treatment such as mechanical manipulation or heat bonding, without weaving, weaving, or knitting, needles, resin-bonded nonwovens, needle punches, spunbonds, and spunlaces. , Emboss films, wet nonwovens, and the like.

Due to its unique low melting point and chemical resistance, polypropylene short fibers are processed into various nonwovens mainly through calendering, needle punching, etc.The general process of manufacturing nonwovens is, for example, carding of short fibers. Through a machine) to manufacture a nonwoven web (web) and thermal bonding it. In order to thermally bond the web, a pair of calendar rollers, a method of using ultrasonic waves, a method of using hot air, and the like are mainly used.

Particularly, in the case of polypropylene short fibers, the fibers are arranged and entangled through an opening and carding process to form a web, which is thermally bonded by a diamond or delta-shaped calender roller and industrially. Non-woven fabric is made of non-woven fabric that can be used for various purposes, or by heating air in a porous drum refluxing the web after carding process by using hot air without using a calender roller. Is prepared.

Polypropylene nonwoven fabric is mainly used for the surface material of sanitary products such as disposable diapers, urinary incontinence diapers, sanitary napkins, masks, sanitary nonwoven fabrics, medical nonwoven fabrics, and filters for automobile interior materials, air filters and water treatment filters. Non-woven fabrics for this purpose do not require as much strength as woven fabrics, but they require secondary processing and strength to be usable, have good physical properties, and should be soft and suitable for the safety of the skin if they are in direct contact with the skin. do.

Republic of Korea Patent No. 774351 has at least one layer of thermoplastic synthetic microfibers having a fiber diameter of 5 µm or less as an intermediate layer, and in a laminated nonwoven fabric integrated by compression, a part of the fine fibers constituting the intermediate layer is one of the long fiber layers. It has a mixed structure layer that enters into more than the cotton to enter index 0.36 or more to bond, embed or entangle long fibers, the basis weight of the laminated nonwoven fabric is 10g or more and 250g / cm2 or less, the bulk density is 0.20 g / cm3 or more A high strength nonwoven fabric is disclosed. However, the patent is made using a polyester resin or a copolymer thereof, and is not a nonwoven fabric produced by forming a filament through a spinneret of a polypropylene melt.

Therefore, it is desired to develop a nonwoven fabric having a high strength property and a nonwoven fabric having a high strength property when producing a fiber through a spinneret of a polypropylene melt.

An object of the present invention to solve the above problems is to provide a high-strength polypropylene short fibers and a nonwoven fabric made of the same.

Another object of the present invention is to provide a soft polypropylene short fibers and a nonwoven fabric made thereof.

In order to achieve the above object, the present invention provides a method for producing a short polypropylene fiber, by blending 90 to 99% by weight of homopolypropylene and 1 to 10% by weight of a carrier resin composed of a copolymer of ethylene and methyl acrylate to melt and Spinning; Stretching and crimping the stretched unstretched yarn at a draw ratio of 3 to 5 and giving a crimp; A surface treatment step of attaching the liquid resin containing the emulsion emulsion to the surface of the crimped stretched yarn; And it provides a high-strength polypropylene short fiber manufacturing method by high stretchability comprising the step of heat-setting the drawn yarn and then cut into short fibers.

 In the present invention, the homopolypropylene has a melt index of 3 to 30 g / 10 min, an isotactic index of 90% or more, and a melting point of 160 to 170 ° C. as measured by DSC. Provided is a method for producing propylene short fibers.

In addition, the carrier resin of the present invention provides a high-strength polypropylene short fiber manufacturing method by high stretch, characterized in that the melt index is 2 to 20g / 10min.

In another aspect, the present invention is characterized in that the high-strength polypropylene short-fiber high strength by high stretchability, characterized in that further comprises one or more additives selected from the group consisting of antioxidants, UV stabilizers, process stabilizers and colorants, including white pigments It provides a method for producing polypropylene short fibers.

In another aspect, the present invention provides a high-strength polypropylene short fiber manufacturing method by high stretch, characterized in that the additive is included 0.1 to 1.5 parts by weight based on 100 parts by weight of high strength polypropylene short fibers.

In addition, the present invention is a high-strength polypropylene with high stretchability, characterized in that in the short polypropylene fiber, 90 to 99% by weight of homopolypropylene and 1 to 10% by weight of a carrier resin made of a copolymer of ethylene and methyl acrylate. Provides short fibers.

In the present invention, the homopolypropylene has a melt index of 3 to 30 g / 10 min, an isotactic index of 90% or more, and a melting point of 160 to 170 ° C. as measured by DSC. Provides short fibers.

In addition, the carrier resin of the present invention provides a high-strength polypropylene short fiber with high stretchability, characterized in that the melt index is 2 to 20g / 10min.

In another aspect, the present invention is characterized in that the high-strength polypropylene short-fiber high strength by high stretchability, characterized in that further comprises one or more additives selected from the group consisting of antioxidants, UV stabilizers, process stabilizers and colorants, including white pigments Provides short polypropylene fibers.

In another aspect, the present invention provides a high-strength polypropylene short fiber with high stretchability, characterized in that the additive contains 0.1 to 1.5 parts by weight based on 100 parts by weight of high strength polypropylene short fiber.

The present invention also provides a polypropylene nonwoven fabric prepared from the high strength polypropylene short fibers by the above high stretchability.

As described above, the short polypropylene fiber according to the present invention has a high strength effect, and thus, a high strength nonwoven fabric can be produced.

In addition, the polypropylene short fibers according to the present invention and the non-woven fabric made thereof have a soft touch effect.

DETAILED DESCRIPTION Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. First, it should be noted that in the drawings, the same components or parts denote the same reference numerals as much as possible. In describing the present invention, detailed descriptions of related well-known functions or configurations are omitted in order not to obscure the subject matter of the present invention.

The terms " about ", " substantially ", etc. used to the extent that they are used herein are intended to be taken to mean an approximation to or in the numerical value of the manufacturing and material tolerances inherent in the meanings mentioned, Accurate or absolute numbers are used to help prevent unauthorized exploitation by unauthorized intruders of the referenced disclosure.

1 is a manufacturing process diagram of polypropylene short fibers according to an embodiment of the present invention.

Short fiber according to an embodiment of the present invention is a high-strength polypropylene short fiber, melted by blending 90 to 99% by weight homopolypropylene and 1 to 10% by weight of a carrier resin consisting of a copolymer of ethylene and methyl acrylate Spinning; Stretching and crimping the stretched unstretched yarn at a draw ratio of 3 to 5 and giving a crimp; A surface treatment step of attaching the liquid resin containing the emulsion emulsion to the surface of the crimped stretched yarn; And high-strength polypropylene short fibers with high stretchability, including the step of heat-setting the stretched yarn and cutting the short fibers into short fibers.

In the melting and spinning step, the melted material is blended with 90 to 99% by weight of homopolypropylene and 1 to 10% by weight of a carrier resin composed of a copolymer of ethylene and methyl acrylate. When prepared within the above range is advantageous for radioactivity and has the effect of improving the strength. If the content of the copolymer of ethylene and methyl acrylate exceeds 10% by weight, a phenomenon of weakening of strength occurs.

Polypropylene polymer for fiber is a material that is very monotonous and regular (90% or more isotactic index), so crystallization easily occurs, and it is compatible with polypropylene and is relatively large. Addition of methyl acrylate, which is a substance, may disturb the alignment of polypropylene polymer chains, thereby increasing the amorphous region, thereby increasing the draw ratio. Therefore, since the draw ratio is higher than that of the general homopolypropylene resin, the strength of the fibers of the short fibers is increased, thereby making it possible to manufacture high-strength nonwoven fabrics. Ethylene is a material that easily forms a graft polymer, thereby preventing splitting of polypropylene polymer chains, thereby suppressing dust generation, and softening the feel of fibers.

In addition, during spinning, the spinning temperature is preferably 230 to 260 ° C. The blended material is spun at a spinning speed of 20 to 100 m / min through spinnerets to produce undrawn yarn.

The homopolypropylene used in the present invention preferably has a melt index (MI) of 3 to 30 g / 10 min, an isotactic index of 90% or more, and a melting point of 160 to 170 ° C. measured by DSC. The lower the melt index of the homopolypropylene can impart fiber stiffness, chemical resistance, and lower elongation, but the viscosity decreases, resulting in poor workability. If the melt index is too high, the stiffness of the fiber is lowered, and spinning Since it is difficult, it is suitable to have a melt index of 3 to 30. If the isotactic index is less than 90%, the radioactivity is not good, there is a problem that the stiffness of the polypropylene short fibers is lowered and the uniformity is inferior. Here, the isotactic means that the normal heptane is boiled to dissolve the atactic component, and the weight of the remaining isotactic component is represented by weight percent.

In addition, the carrier resin is made of a copolymer of ethylene and methyl acrylate, the melt index is preferably 2 to 20g / 10min.

The spun unstretched yarn is subjected to a stretching and crimping process, the stretching ratio is properly adjusted between 3.0 to 5.0, the stretching roll temperature is stretched to 50 to 100 ℃. The stretched yarn is imparted crimp in the crimper. When the draw ratio exceeds 5.0, trimming occurs frequently during the soft work.

The crimped stretched yarn that is crimped is then subjected to a step of attaching an emulsion, which may be hydrophilic or hydrophobic, depending on the purpose of the final product. Dipping (Deeping) or spray (Spray) treatment of the stretched yarn crimped to the liquid resin containing the oil to allow the oil to adhere to the stretched yarn.

Meanwhile, in addition to the emulsion, one or more additives selected from the group consisting of antioxidants, UV stabilizers, process stabilizers, and colorants including white pigments may be optionally further included, and the content of such additives may be 100 parts by weight of polypropylene short fibers. It is preferably included in 3 parts by weight or less, more preferably 0.1 to 1.5 parts by weight. When the content is exceeded, problems of deterioration of physical properties and productivity are caused.

The stretched yarn with the emulsion is heat-set for about 8 to 12 minutes at a temperature of 100 to 120 ° C., and then cut to have a fiber length of 40 to 100 mm to target a final fiber fineness of 1.5 to 10 denier and an average elongation of 50 to 400%. The polypropylene short fiber can be manufactured.

Figure 2 is a manufacturing process of the nonwoven fabric using the needle punching method according to an embodiment of the present invention.

Short polypropylene fiber according to the present invention has a problem that the heat fusion is not well made when manufactured through a thermal bond method for producing a nonwoven fabric through the heat bonding bar having a high strength characteristics, using the needle punching method It is desirable to produce nonwovens.

First, the nonwoven fabric through the needle punching process of the present invention may proceed to the other surface step, carding step, forming step, nonwoven fabric forming step.

The high-strength polypropylene short fibers produced in the short fiber manufacturing step is carried out in the other surface stage on the other side machine equipped with a fixed quantity supply device. After the carding step proceeds to the carding at a speed of 80 to 150 mpm (m / min) to the carding machine to manufacture the other short fibers in a certain width and thickness of the web (Web), the web through the carding step (Web) In the molding machine disposed below the upright of the card machine, a molding step of laminating webs as many times as necessary is performed based on the quality and shape required for the product. Subsequently, the molded web (Web) enhances a strong bonding force and tensile strength, and proceeds to the nonwoven fabric forming step of manufacturing a nonwoven fabric by needle punching method for the solidification of the product prototype, the final required nonwoven fabric is completed.

Hereinafter, embodiments of the present invention will be described in detail. Conditions and test results of each Example and Comparative Examples can be summarized in the following [Table 1].

Example 1

(Production of Polypropylene Short Fiber)

When the homopolypropylene resin is melted at a spinning temperature of about 250 ° C., a carrier resin composed of a copolymer of ethylene and methyl acrylate is blended by 5% by weight and spun at a spinning speed of about 100 m / min through a spinneret to produce undrawn yarn. It was.

The non-drawn yarn is drawn at a draw ratio of 3 and drawn at a stretching roll temperature of 50 to 100 ° C., and then crimped in a crimper, and the liquid resin containing a hydrophilic emulsion is dipped or sprayed to give a total amount of the short fiber. An oil agent is attached to the fiber surface so that 1 part by weight is contained per 100 parts by weight, heat-fixed at about 100 ° C. for 10 minutes, and the fibers are cut to 64 mm in length so that the final fiber fineness is 2.0 to 10 denier and average elongation. To produce a polypropylene short fiber aimed at 50 to 400%.

(Production of Polypropylene Nonwovens)

In the production of the polypropylene nonwoven fabric, the polypropylene short fibers obtained by the above method were carded at a speed of 80 to 150mpm with a carding machine, a nonwoven web was prepared, and a nonwoven fabric was manufactured by needle punching to measure physical properties such as tensile strength.

Examples 2 and 3

The same procedure as in Example 1 was conducted except that 1 wt% and 10 wt% of a carrier resin composed of a copolymer of ethylene and methyl acrylate was blended to prepare short fibers.

Examples 4-6

In the same manner as in Examples 1 to 3, respectively, the draw ratio of the non-drawn yarn was 5 to prepare short fibers.

Comparative Example 1

In the same manner as in Example 1, homopolypropylene alone was performed without blending a carrier resin composed of a copolymer of ethylene and methyl acrylate, thereby preparing short fibers and a nonwoven fabric.

※ Analysis method

1. Melt Index (MI): According to ASTM D 1238

   * Propylene and random copolymer series: 230 ℃, 2.16kg load

   * PE series such as HDPE, LDPE: 190 ℃, 2.16kg load

2. Isotactic Index (II): ISO 9113: 1986Plastics-Polypropylene (PP) and propylene-copolymer thermoplastics-Determination of isotactic index: Isotac remaining after boiling normal heptane to dissolve the atactic component The tick component is weighed and expressed as weight percent, which is referred to as isotactic index.

3.Xylene Soluble (hereinafter referred to as XS): ISO 16152: 2005

4. Radioactivity: Evaluated by measuring the number of fiber breaks and the number of spin drops generated immediately under the detention of 11,000 to 65,000 holes.

         However, trimming or dropping is less than once / hour: ◎

         However, trimming or dropping is 1 ~ 3 times / time: ○

         Only three times / time of drop or drop: △

         No radiation: ×

5. Elongation: Emissive during soft work

          Less than 1 time / hour: ○, 1 ~ 2 times / time: △, More than 3 times / hour: ×

6. Crimping workability: The number of times the stretched tow failed by passing through the crimper by visual observation.

   Less than 1 time / hour: ○, 1 ~ 2 times / time: △, More than 3 times / hour: ×

7. Single fiber fineness: Determination of fineness based on ASTM D1577

8. Short fiber strength / elongation measurement: Strength / elongation measurement based on DIN 53816

9. Non-woven carding property: When short fiber passes through carding machine, curling or flying phenomenon occurs between card rolls, or when web formation is not good.

10. Basis weight: weight of nonwoven

11. Tensile strength and elongation of nonwoven fabric: Cut-strip method of JIS L 1096 (sample width 5cm, length 14cm)

   MD: Machine direction of nonwoven fabric, CD: Transverse direction of nonwoven fabric

12. Equalizer: 1 (bad) ~ 5 (very good)

division Workability and Physical Properties of Fiber Workability and Properties of Nonwovens Radioactive Elongation Crimping workability Island
(De) burglar
(g / De) Shindo
(%) Carding Leveling system burglar MD CD Example 1 ◎ ○ ○ 5.1 5.24 113 Good 4 18.4 21.6 Example 2 ◎ ○ ○ 5.0 4.98 94 Good 5 16.5 18.2 Example 3 ◎ ○ ○ 5.0 5.43 126 Good 5 21.7 23.4 Example 4 ◎ ○ ○ 4.9 5.87 76 Good 5 23.5 25.2 Example 5 ◎ ○ ○ 5.2 5.51 62 Good 4 21.6 24.3 Example 6 ◎ ○ ○ 5.1 6.04 84 Good 4 24.8 27.5 Comparative Example 1 ○ ○ ○ 3.7 4.23 80 Good 3 13.1 16.9

※ Experiment result

Polypropylene short fibers and nonwoven fabrics prepared from the above Examples 1 to 6 are excellent in stretchability even when working through a high draw ratio, and the polypropylene short fibers and nonwoven fabrics are made of homopropylene alone. It can be seen that the comparison is very high.

The present invention described above is not limited to the above-described embodiment and the accompanying drawings, and various substitutions, modifications, and changes are possible within the scope without departing from the technical spirit of the present invention. It will be evident to those who have knowledge of.

1 is a manufacturing process diagram of polypropylene short fibers according to an embodiment of the present invention.

Figure 2 is a manufacturing process of the nonwoven fabric according to an embodiment of the present invention.

Claims (11)

In the method for producing polypropylene short fibers, Melting and spinning by blending 90 to 99% by weight of homopolypropylene and 1 to 10% by weight of a carrier resin consisting of a copolymer of ethylene and methyl acrylate; Stretching and crimping the stretched unstretched yarn at a draw ratio of 3.0 to 5.0 and giving a crimp; A surface treatment step of attaching the liquid resin containing the emulsion emulsion to the surface of the crimped stretched yarn; And A high-strength polypropylene short fiber manufacturing method by high stretchability comprising the step of heat-setting the drawn yarn and cutting into short fibers. The method of claim 1,  Melt index of the homopolypropylene is 3 to 30g / 10min, isotactic index is 90% or more, the melting point measured by DSC is 160 to 170 ℃ high strength polypropylene short-fiber manufacture Way. The method of claim 1, The carrier resin is a high-strength polypropylene short fiber manufacturing method by high stretch, characterized in that the melt index is 2 to 20g / 10min. The method of claim 1, The high-strength polypropylene short fibers with high stretchability, characterized in that the high-strength polypropylene short fibers are optionally further included at least one additive selected from the group consisting of antioxidants, ultraviolet stabilizers, process stabilizers and colorants, including white pigments. Manufacturing method. The method of claim 4, wherein The additive is a high-strength polypropylene short fiber manufacturing method by high stretch, characterized in that 0.1 to 1.5 parts by weight based on 100 parts by weight of high strength polypropylene short fibers. In polypropylene short fibers, High-strength polypropylene short fibers with high stretchability, characterized in that it comprises 90 to 99% by weight homopolypropylene and 1 to 10% by weight of a carrier resin consisting of a copolymer of ethylene and methyl acrylate. The method of claim 6, A high-strength polypropylene short fiber with high stretchability, characterized in that the melt index of the homopolypropylene is 3 to 30 g / 10 min, the isotactic index is 90% or more, and the melting point measured by DSC is 160 to 170 ° C. The method of claim 6, The carrier resin is a high-strength polypropylene short fiber with high stretchability, characterized in that the melt index is 2 to 20g / 10min. The method of claim 6, The high-strength polypropylene short fibers with high stretchability, characterized in that the high-strength polypropylene short fibers are optionally further included at least one additive selected from the group consisting of antioxidants, ultraviolet stabilizers, process stabilizers and colorants, including white pigments. . 10. The method of claim 9, The additive is a high-strength polypropylene short fiber with high stretchability, characterized in that 0.1 to 1.5 parts by weight based on 100 parts by weight of high strength polypropylene short fibers. A polypropylene nonwoven fabric made from high strength polypropylene short fibers with high stretchability according to any one of claims 1 to 10.

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